Pile fabric



March 4, 1930. J, P, s-TROUD f 1,749,551

PILE FABRIC Filed Feb. 27. 1928 2 Sheets-Sheet l Wl TN ESSES @www MW B Y ATTORNEY Patented Mar. 4, 1930 v1 .1 .TE1-JT OFFICE JAMES P. s'rRouD, oFNoBLE, rENNsYLvANIA PILE FABRIC Original application led August 2, 1926, Serial No. 126,375. Divided and this application filed February 27, 1923.r Serial No. 257,387. 4

cessation in operation of the mechanism by which the pile wires are manipulated to form the pile loops.

To the attainment of the foregoing m in.

vention essentially consists in forming s eds with a certain few of the face warps incident I to weaving the blank spaces aforesaid, thereby to enable continuous usev of the wires about which the pile loops are formed.

. Further objects and attendant advantages will -be readily apparent from the detailed description which follows of the typical embodiment of my invention shown in the drawings, whereof Fig. I isl a perspective view illustrating, in a diagrammatic way, l how 'a series of individual rugs are woven 1n continuous succession in'accordance with the present improvements.

Fig. II is a cross-sectional view of one of the rugs taken as indicated by the arrows II-II in Fig. I.

taken as indicated by the arrows III-II in Fig. I.

Fig. IV is a view showing the weave in thev Fig. III is a view similar to the precedin ammatic views I, conventionally showing the texture of a typical weave convenient to my invention.

In carrying out my invention, I preferably weave the rugs in continuous succession as depicted in Fig. I, wherein the individual rugs are designated by the numeral 10, and shown as separated by blank intervals 11. In the present instance, each rug is characterized by a border 12 that surrounds a center eld 13, both formed of pile facing tufts upstanding from the ground weave 14; which, as shown, is extended laterally along opposite side edges as at 15, 15 and also constitutes the blank intervals 11 aforesaid. For a purpose later on explained, a certain few of the face or pile warps are maintained in action during weaving of the blank intervals 11 with consequent formation of connecting lines 16 of tufts that are; subsequently removed by hand or otherwise. After weaving, the individual rugs 10 are cut apart along lines 17 medially of the blank intervals 11, a margin of the ground weave 14 being thus left at the ends of each rug. These end mar# gins, as well as the side `margins 15 already mentioned, are .afterwards under-folded and sewedl fast with consequent provision of heavy reinforced perimetric edges which will lie perfectly lat on the floor and thus resist bein-g readily upturned. It is to be particu- 'larly noted that the folds are so allocated` that the piling is carried around the rug edges which adds greatly to the attractiveness of the finish.

In accordance with the present invention, distinction in appearance as between the border areas 12 and the center areas 13 of the rugs 10 is predetermined through a novel physical treatment incidental to initial preparation of the warps 18, 20 (Figs. IV'and VIII from which the facing pile tufts T, T in t e yaforesaid areas are respectively formed. As shown in Fig. VI, the component strands 19, 19 of the warps 18 are individually twisted loosely-both in one directionand plied by twisting in the opposite d irection so as to be neutralized against recoiling subsequentl when the loops L (Fi .IV) are severed to orm the tufts T (Fig. III) incidental to withdrawal of the loop forming l straight and are therefore seen end on in the borders l2 of the rugs.

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On the other hand, the warps 20, constltuting the center field facing of the rugs 10, are composed, as con-Y ventionally indicated in Fig. VII, of strands 21, 21 which are individually hard twistedboth in one direction-and plied by close twisting in the same direction. the hard twisting all in the one direction, the tufts T (Figi VIII), produced upon cutting the pile loops L (Fig. IV) that are formed from the warps 20, contract in the direction of their length and open up somewhat at the ends incidental to recoiling as a result of which the center field areas 13 sink somewhat below the level of the borders 12, as shown in Figs. II, andv VIII. These tufts T moreover, take the -form of' permanent curls with consequent impartation of a rough appearance to the center` fields 13 which accordingly stand out in marked co'n` trastv to the smoother appearing border areas 12, all as conventionally illustrated in the drawings. When face warps of silk or other gloss material are employed, the distinction is'heightened through contrast of the sheen of the tuft fibers visible sidewise in the center fields 13 lwith the more somber or subduediborders 12 wherein the tuft fibers are seen end on. While I have described the face warps 18, 20 as being two ply, it is obvious that the number of plies as well as the extent of relative twistingfmay be varied indefinitely in actual practice.

The ground weave 14 suitable to my invention is susceptible of extensive diversication, and the one shown in F igs..IV and VIII is therefore to be considered typical of many other possible forms. In the present instance, it involves, in addition to the face warps 18, 20, a layer of stuifer warps 22 which are inlaid between upper and lower shuttle or weft threads 23, 24, the whole being tied together by binder warps designated 25, 25. The distinguishing feature to be particularly remarked in the illustrated fabric is that the warps 18 are concealed in the ground fabric with the stuffer warps 22 throughout the entire center field area 13, and. conversely, that the'face warps 2O are suppressedin the border area`12 and there- .y

fore serve in the capacity of stufers in that ,face warps 18, 20 and in the arrangement and control of the harnesses governing formation of thesheds. 4 Thus in Fig. V, the end border warps 18,for the border sides-are Owing tosupplied from the beam 18'L and passed through heddles of a harness frame 18". The center field warps 20 for the side'portions of the borders are-in turn-supplied b'y a beam 20, and controlled by a harness frame 20". The stuli'er warps 22 are wound on a beam '22* and may be guided through elongated eyes.

in the harness frames 18b and 20"; while the binder warps 25 are supplied from a beam 25a, alternate ends being passed through separate harness frames 25h and 25C. In addition, an auxiliary beam 26 and an associated harness .26a are employed for the few isolated face warps by which the connecting tufts 16 (Fig. I) are formed across the intervals 11. 4By means of drop rods 27 the several harness frames are coordinated with .roller arms 28 pivoted in the lower part of the loom, and adapted to be actuated individually by suitable cams on the cam shaft 29. The tuft loops L, L (Fig.'IV) are set up in the customary manner through cooperation between the lay reed shown at 30 in Fig.. V, .with the pile forming Vwires W previously mentioned. The loom is of course equipped with the usual mechanism (not shown) for automatically inserting and .withdrawing the pile formto be suppressed in the ground weavelll of the fabric. This may be accomplished by manual disconnection of the heddle frames 18b and 20", or by any suitable automatic means for the purpose. The use of a separate harness frame 26a to maintain the Cfew isolated face warps in constant action during weaving, of the rugs is also considered novel. This is advantageous in that the operat-ion of the loom is rendered continuous since it obviates the necessity for manual withdrawal of the pile wires W--incidental to weaving of the blank intervals 11, as well as subsequent manual reinsertion of said wires at the beginning of each new rug 10 as would otherwise be the case.

It is of course lpossible, within the scope of my invention, to produce designs other than the plainA border variety herein shown, and, while marked dierences'in surface appearance are'obtainable with yarns all one color and material, more vivid contrasts may obviously be had by employment of yarns of different colors and materials,tor with yarns whose appearanc'eis affected through variation in chemical treatment incidental to preparation initially. p

After weaving and completion of the individual rugs 10 they may be subjected to aV aming operation to emphasize the curl of the T inthe center `field areas 13 and to open up the tufts T of the border areas 12 ing lines of to themaxilnum fullness.

lflaving described my invention, what I claim, and desire to secure by Letters Patent, 1s 1 l '1. The method of manufacturing pile fabric articles in continuous succession with blank side margins and intervening blank portions whichconsists in maintaining acertain few of the face warps in action incident to weaving the blank portions aforesaid with consequent production of connecting lines of pile tufts at intervals thereacross and thereby to enable continuous use of the wires about which the pile loops are formed, and severing the material so produced across the blank portions linto individual articles.

f 2. The method of manufacturing pile fabric articles in continuous succession with ound weave side margins and intervening lank portions which consists in maintaining ya certaln few of the face warps in action incident to weaving the blank ortions aforesaid with consequent productlon of connecting linesof pile tufts at intervals thereacross and thereby to enable continuous use of the wires about which the pile loops are formed ysevering the individual articles medially o the blank portions,and removing the connectsl pile tufts from said blank portions.

v3.v The methodof manufacturing pile fabi ric rugs in continuous succession with ground weave. side marginsl and'intervening blank portions whichl consists in maintaining a certain few of the face warps in action incident to weaving the blank portions aforesaid with consequent production of connecting lines of pile tufts atinterv'als thereacross and thereby to .enable continous use of the wires about which the p ile loops are formed, severing the individual rugs medially of the blank portions, removing the connecting lines of pile tufts from the blank end portions, and underfolding and-uniting said end blank portions-fas well as corre onding side margins-to the back of the 11e fabrlc.

In testimony whereo I have hereunto signed my name at Philadelphia, Pennsylf vania, this 16th day of February, 1928.

l l A JAME S P. STROUD. 

